AU8660098A - Polyhydroxyalkanoate molding compositions - Google Patents
Polyhydroxyalkanoate molding compositions Download PDFInfo
- Publication number
- AU8660098A AU8660098A AU86600/98A AU8660098A AU8660098A AU 8660098 A AU8660098 A AU 8660098A AU 86600/98 A AU86600/98 A AU 86600/98A AU 8660098 A AU8660098 A AU 8660098A AU 8660098 A AU8660098 A AU 8660098A
- Authority
- AU
- Australia
- Prior art keywords
- composition
- polyhydroxyalkanoate
- binder
- powdered material
- powder
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 239000005014 poly(hydroxyalkanoate) Substances 0.000 title claims abstract description 101
- 229920000903 polyhydroxyalkanoate Polymers 0.000 title claims abstract description 101
- 239000000203 mixture Substances 0.000 title claims abstract description 80
- 238000000465 moulding Methods 0.000 title claims abstract description 26
- 238000000034 method Methods 0.000 claims abstract description 32
- 229910052751 metal Inorganic materials 0.000 claims abstract description 31
- 239000002184 metal Substances 0.000 claims abstract description 31
- 239000000919 ceramic Substances 0.000 claims abstract description 25
- 238000001746 injection moulding Methods 0.000 claims abstract description 15
- 239000012254 powdered material Substances 0.000 claims abstract description 15
- 238000001125 extrusion Methods 0.000 claims abstract description 7
- 238000010345 tape casting Methods 0.000 claims abstract description 5
- 238000007569 slipcasting Methods 0.000 claims abstract description 4
- 229920000642 polymer Polymers 0.000 claims description 29
- 239000000243 solution Substances 0.000 claims description 14
- 229920000331 Polyhydroxybutyrate Polymers 0.000 claims description 12
- 238000010438 heat treatment Methods 0.000 claims description 12
- 239000005015 poly(hydroxybutyrate) Substances 0.000 claims description 12
- 150000002739 metals Chemical class 0.000 claims description 10
- 239000002904 solvent Substances 0.000 claims description 9
- 229920001577 copolymer Polymers 0.000 claims description 8
- -1 poly(hydroxybutyrate) Polymers 0.000 claims description 8
- 239000000126 substance Substances 0.000 claims description 6
- 229920000747 poly(lactic acid) Polymers 0.000 claims description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 5
- 239000011521 glass Substances 0.000 claims description 4
- 230000000813 microbial effect Effects 0.000 claims description 4
- 229920006324 polyoxymethylene Polymers 0.000 claims description 4
- NYHNVHGFPZAZGA-UHFFFAOYSA-N 2-hydroxyhexanoic acid Chemical compound CCCCC(O)C(O)=O NYHNVHGFPZAZGA-UHFFFAOYSA-N 0.000 claims description 3
- 239000000956 alloy Substances 0.000 claims description 3
- 229910045601 alloy Inorganic materials 0.000 claims description 3
- 238000003825 pressing Methods 0.000 claims description 3
- 238000007650 screen-printing Methods 0.000 claims description 3
- 229920000954 Polyglycolide Polymers 0.000 claims description 2
- 239000004793 Polystyrene Substances 0.000 claims description 2
- 229910052736 halogen Inorganic materials 0.000 claims description 2
- 125000004435 hydrogen atom Chemical group [H]* 0.000 claims description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N nitrogen Chemical group N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 2
- 229910052757 nitrogen Inorganic materials 0.000 claims description 2
- QJGQUHMNIGDVPM-UHFFFAOYSA-N nitrogen group Chemical group [N] QJGQUHMNIGDVPM-UHFFFAOYSA-N 0.000 claims description 2
- 229920000098 polyolefin Polymers 0.000 claims description 2
- 229920002223 polystyrene Polymers 0.000 claims description 2
- 238000007151 ring opening polymerisation reaction Methods 0.000 claims description 2
- 229920006395 saturated elastomer Polymers 0.000 claims description 2
- 229930195734 saturated hydrocarbon Natural products 0.000 claims description 2
- 229930195735 unsaturated hydrocarbon Natural products 0.000 claims description 2
- 239000001993 wax Substances 0.000 claims description 2
- 238000006116 polymerization reaction Methods 0.000 claims 2
- 238000006243 chemical reaction Methods 0.000 claims 1
- 238000000855 fermentation Methods 0.000 claims 1
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- 229920000515 polycarbonate Polymers 0.000 claims 1
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- 239000011230 binding agent Substances 0.000 abstract description 58
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- 238000012545 processing Methods 0.000 abstract description 10
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- 239000000463 material Substances 0.000 description 15
- 239000002245 particle Substances 0.000 description 14
- 239000000047 product Substances 0.000 description 14
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 12
- 230000015572 biosynthetic process Effects 0.000 description 10
- 238000004519 manufacturing process Methods 0.000 description 10
- 238000000354 decomposition reaction Methods 0.000 description 9
- 239000004816 latex Substances 0.000 description 9
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- 229920002521 macromolecule Polymers 0.000 description 8
- 230000000717 retained effect Effects 0.000 description 8
- 230000004580 weight loss Effects 0.000 description 8
- 230000007547 defect Effects 0.000 description 7
- 229920000520 poly(3-hydroxybutyrate-co-3-hydroxyvalerate) Polymers 0.000 description 7
- 241000589776 Pseudomonas putida Species 0.000 description 6
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- 238000002485 combustion reaction Methods 0.000 description 6
- 235000014113 dietary fatty acids Nutrition 0.000 description 6
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- 229930195729 fatty acid Natural products 0.000 description 6
- 150000004665 fatty acids Chemical class 0.000 description 6
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 6
- 238000002844 melting Methods 0.000 description 6
- 230000008018 melting Effects 0.000 description 6
- 238000009472 formulation Methods 0.000 description 5
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- 239000002253 acid Substances 0.000 description 4
- 239000000654 additive Substances 0.000 description 4
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 4
- 239000003795 chemical substances by application Substances 0.000 description 4
- 239000010931 gold Substances 0.000 description 4
- 229910052737 gold Inorganic materials 0.000 description 4
- 229920001519 homopolymer Polymers 0.000 description 4
- 229910044991 metal oxide Inorganic materials 0.000 description 4
- 150000004706 metal oxides Chemical class 0.000 description 4
- 244000005700 microbiome Species 0.000 description 4
- 239000001301 oxygen Substances 0.000 description 4
- 229910052760 oxygen Inorganic materials 0.000 description 4
- 238000005245 sintering Methods 0.000 description 4
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- 238000005979 thermal decomposition reaction Methods 0.000 description 4
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- WHBMMWSBFZVSSR-GSVOUGTGSA-N (R)-3-hydroxybutyric acid Chemical group C[C@@H](O)CC(O)=O WHBMMWSBFZVSSR-GSVOUGTGSA-N 0.000 description 3
- 150000007513 acids Chemical class 0.000 description 3
- 239000012620 biological material Substances 0.000 description 3
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- 238000002425 crystallisation Methods 0.000 description 3
- 230000008025 crystallization Effects 0.000 description 3
- 238000009792 diffusion process Methods 0.000 description 3
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- 239000004416 thermosoftening plastic Substances 0.000 description 3
- WHBMMWSBFZVSSR-GSVOUGTGSA-M (R)-3-hydroxybutyrate Chemical compound C[C@@H](O)CC([O-])=O WHBMMWSBFZVSSR-GSVOUGTGSA-M 0.000 description 2
- QPLDLSVMHZLSFG-UHFFFAOYSA-N Copper oxide Chemical compound [Cu]=O QPLDLSVMHZLSFG-UHFFFAOYSA-N 0.000 description 2
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 2
- 239000003082 abrasive agent Substances 0.000 description 2
- 125000004432 carbon atom Chemical group C* 0.000 description 2
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 2
- 230000003197 catalytic effect Effects 0.000 description 2
- 239000000470 constituent Substances 0.000 description 2
- 238000002474 experimental method Methods 0.000 description 2
- 238000010304 firing Methods 0.000 description 2
- 230000009477 glass transition Effects 0.000 description 2
- 239000008187 granular material Substances 0.000 description 2
- 229910017604 nitric acid Inorganic materials 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 229920002795 polyhydroxyoctanoate Polymers 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 238000007493 shaping process Methods 0.000 description 2
- 239000011800 void material Substances 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 229910021521 yttrium barium copper oxide Inorganic materials 0.000 description 2
- MNRBGFKCVTVNBA-UHFFFAOYSA-N 2-Hydroxyundecanoate Chemical compound CCCCCCCCCC(O)C(O)=O MNRBGFKCVTVNBA-UHFFFAOYSA-N 0.000 description 1
- YDZIJQXINJLRLL-UHFFFAOYSA-N 2-hydroxydodecanoic acid Chemical group CCCCCCCCCCC(O)C(O)=O YDZIJQXINJLRLL-UHFFFAOYSA-N 0.000 description 1
- RGMMREBHCYXQMA-UHFFFAOYSA-N 2-hydroxyheptanoic acid Chemical compound CCCCCC(O)C(O)=O RGMMREBHCYXQMA-UHFFFAOYSA-N 0.000 description 1
- BTJFTHOOADNOOS-UHFFFAOYSA-N 2-hydroxynonanoic acid Chemical compound CCCCCCCC(O)C(O)=O BTJFTHOOADNOOS-UHFFFAOYSA-N 0.000 description 1
- JKRDADVRIYVCCY-UHFFFAOYSA-N 2-hydroxyoctanoic acid Chemical compound CCCCCCC(O)C(O)=O JKRDADVRIYVCCY-UHFFFAOYSA-N 0.000 description 1
- HPMGFDVTYHWBAG-UHFFFAOYSA-N 3-hydroxyhexanoic acid Chemical compound CCCC(O)CC(O)=O HPMGFDVTYHWBAG-UHFFFAOYSA-N 0.000 description 1
- SJZRECIVHVDYJC-UHFFFAOYSA-M 4-hydroxybutyrate Chemical compound OCCCC([O-])=O SJZRECIVHVDYJC-UHFFFAOYSA-M 0.000 description 1
- SJZRECIVHVDYJC-UHFFFAOYSA-N 4-hydroxybutyric acid Chemical group OCCCC(O)=O SJZRECIVHVDYJC-UHFFFAOYSA-N 0.000 description 1
- 241000894006 Bacteria Species 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical group [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 description 1
- 229920001634 Copolyester Polymers 0.000 description 1
- CODXQVBTPQLAGA-UHFFFAOYSA-N Hydroxydecanoate Chemical compound CCCCCCCCCC(=O)OO CODXQVBTPQLAGA-UHFFFAOYSA-N 0.000 description 1
- 239000006057 Non-nutritive feed additive Substances 0.000 description 1
- 235000014676 Phragmites communis Nutrition 0.000 description 1
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- WHBMMWSBFZVSSR-UHFFFAOYSA-N R3HBA Natural products CC(O)CC(O)=O WHBMMWSBFZVSSR-UHFFFAOYSA-N 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- DPXJVFZANSGRMM-UHFFFAOYSA-N acetic acid;2,3,4,5,6-pentahydroxyhexanal;sodium Chemical compound [Na].CC(O)=O.OCC(O)C(O)C(O)C(O)C=O DPXJVFZANSGRMM-UHFFFAOYSA-N 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- AYJRCSIUFZENHW-DEQYMQKBSA-L barium(2+);oxomethanediolate Chemical compound [Ba+2].[O-][14C]([O-])=O AYJRCSIUFZENHW-DEQYMQKBSA-L 0.000 description 1
- 229920002988 biodegradable polymer Polymers 0.000 description 1
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- 238000005266 casting Methods 0.000 description 1
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- 230000001427 coherent effect Effects 0.000 description 1
- 239000000567 combustion gas Substances 0.000 description 1
- 238000009264 composting Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- LDHQCZJRKDOVOX-NSCUHMNNSA-N crotonic acid Chemical compound C\C=C\C(O)=O LDHQCZJRKDOVOX-NSCUHMNNSA-N 0.000 description 1
- 229960004643 cupric oxide Drugs 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000007872 degassing Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000018109 developmental process Effects 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
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- 229920001971 elastomer Polymers 0.000 description 1
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- 229920002313 fluoropolymer Polymers 0.000 description 1
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- 239000003517 fume Substances 0.000 description 1
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 239000007943 implant Substances 0.000 description 1
- 210000003000 inclusion body Anatomy 0.000 description 1
- 150000002596 lactones Chemical class 0.000 description 1
- 230000000670 limiting effect Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 230000001050 lubricating effect Effects 0.000 description 1
- WSFSSNUMVMOOMR-NJFSPNSNSA-N methanone Chemical compound O=[14CH2] WSFSSNUMVMOOMR-NJFSPNSNSA-N 0.000 description 1
- 239000011859 microparticle Substances 0.000 description 1
- 239000004005 microsphere Substances 0.000 description 1
- 239000011812 mixed powder Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 239000002105 nanoparticle Substances 0.000 description 1
- 239000006259 organic additive Substances 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 239000004482 other powder Substances 0.000 description 1
- SIWVEOZUMHYXCS-UHFFFAOYSA-N oxo(oxoyttriooxy)yttrium Chemical compound O=[Y]O[Y]=O SIWVEOZUMHYXCS-UHFFFAOYSA-N 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 230000037361 pathway Effects 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- UQGPCEVQKLOLLM-UHFFFAOYSA-N pentaneperoxoic acid Chemical compound CCCCC(=O)OO UQGPCEVQKLOLLM-UHFFFAOYSA-N 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
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- 238000000194 supercritical-fluid extraction Methods 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
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- 239000004634 thermosetting polymer Substances 0.000 description 1
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- LDHQCZJRKDOVOX-UHFFFAOYSA-N trans-crotonic acid Natural products CC=CC(O)=O LDHQCZJRKDOVOX-UHFFFAOYSA-N 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- 239000003981 vehicle Substances 0.000 description 1
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Classifications
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- C—CHEMISTRY; METALLURGY
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/62605—Treating the starting powders individually or as mixtures
- C04B35/62645—Thermal treatment of powders or mixtures thereof other than sintering
- C04B35/62655—Drying, e.g. freeze-drying, spray-drying, microwave or supercritical drying
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F1/107—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing organic material comprising solvents, e.g. for slip casting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
- B22F3/1017—Multiple heating or additional steps
- B22F3/1021—Removal of binder or filler
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
- C04B35/111—Fine ceramics
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/46—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates
- C04B35/462—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates based on titanates
- C04B35/465—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates based on titanates based on alkaline earth metal titanates
- C04B35/468—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates based on titanates based on alkaline earth metal titanates based on barium titanates
- C04B35/4682—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates based on titanates based on alkaline earth metal titanates based on barium titanates based on BaTiO3 perovskite phase
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C04B35/632—Organic additives
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- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
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- C04B35/634—Polymers
- C04B35/63404—Polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- C04B35/63408—Polyalkenes
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- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
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Abstract
Molding compositions including polyhydroxyalkanoates are provided. The use of polyhydroxyalkanoates as a binder in molding compositions provides improved binder removal in the finished molded product, and offers a wide range of physical properties suitable for use in a variety of processing conditions. The composition preferably includes a powdered material, such as a metal powder, ceramic powder, or blend, admixed with a polyhydroxyalkanoate binder. The compositions are useful in powder processing techniques, such as injection molding, slip casting, tape casting, or extrusion.
Description
WO 99/05209 PCT/US98/15195 POLYHYDROXYALKANOATE MOLDING COMPOSITIONS Cross-Reference To Related Applications Priority is claimed to U.S. Provisional application Serial No. 60/053,380, filed July 22, 1997. 5 Background Of The Invention The present invention is generally in the field of compositions for forming molding articles, and more particularly to compositions including powdered forms of glass, ceramic, metals, and thermoplastics. A variety of useful molded products having complex shapes and 10 useful mechanical strengths can be made from powdered forms of ceramics, metals, metal oxides, thermoset resins, high melt temperature thermoplastics, and combinations thereof. Examples of these products include aerospace components, biomedical implants, bonded diamond abrasives, cutting tools, engine and other mechanical parts, nozzles 15 subject to continuous contact with abrasives, electronic devices, and superconductors. Forming techniques, such as slip casting, tape casting, extrusion, injection molding, dry pressing and screen printing, generally require the presence of a binder formulation that is mixed with the metal, ceramic, or mixed powder feed. The binder is a temporary vehicle for 20 homogeneously packing the powder into the desired shape and then for holding the particles in that shape until the beginning of sintering (German, "Powder Injection Molding," (Metal Powder Industries Federation, Princeton, New Jersey 1990); German and Bose, "Injection Molding of Metals and Ceramics," (Metal Powder Industries Federation, 25 Princeton, New Jersey 1997)). Sintering, or fusing, of the powder components is needed, for example, to obtain physical properties for the finished item that are suitable for the conditions of its end use. Sintering is an important process for thermoplastic resins, such as polyimides and fluoropolymers, that do not have a well-defined melt phase (Strong, 1 WO 99/05209 PCTIUS98/15195 "Plastics: Materials and Processing," (Prentice-Hall, Inc., Englewood Cliffs, New Jersey 1996)). One disadvantage with using traditional binders in the shape formation is that the molded product's physical properties and 5 performance can be impaired by residual amounts of binder or binder decomposition products, by uneven removal of binder or binder decomposition products, or by voids formed by removal of binder or binder decomposition products. (Residual binder is not a problem in the limited circumstances when it is desirable to incorporate binder 10 components into the final form by chemical or interatomic attraction.) Many products made from ceramic powders, metal powders, and blends thereof are used in applications where they are exposed to repeated stresses. Examples of these products include combustion engine parts, valves, rotors, and gear assemblies. Inclusion bodies derived from 15 inadequate removal of binder, or voids resulting from combustion gases during removal, can facilitate cracking and failure of the parts in service. Electrical conductivity is another important performance requirement, for example in electronic parts such as printed circuit boards and superconductors, that can be adversely affected by inadequate binder 20 removal or void formation caused thereby. Therefore, removal of the binder used in shape formation is generally a crucial step in the powder processing technique. Techniques for the removal of undesirable binders include (1) thermal evaporation; (2) thermal decomposition; (3) chemical 25 transformation to forms useful in the end product; (4) solvent extraction; (5) supercritical extraction; (6) diffusion and absorption of binder constituents to an absorbing surface surrounding the shape or wicking; and (7) depolymerization by thermal means, catalytic means, or a combination thereof. Removal of the binder usually is the slowest step in 30 the powder injection molding process (German, "Sintering Theory and Practice," (John Wiley & Sons, New York 1996); German and Bose, "Injection Molding of Metals and Ceramics," (Metal Powder Industries 2 WO 99/05209 PCT/US98/15195 Federation, Princeton, New Jersey 1997)). One binding system investigated for providing more rapid removal involves using polyacetals, particularly with injection molding processing, for example, as described in U.S. Patent No. 5,155,158 to Kim and in WO 91/08993. The use of 5 polyalkylene carbonates for use in such applications is disclosed in European Patent Application EP 0,463,769 A2. In theory, the polyacetal binders "unzip" or depolymerize, releasing formaldehyde, when exposed to nitric acid fumes in an incubator. Similarly, the polyalkylene carbonate binders "unzip" upon reaching a certain decomposition 10 temperature, typically around 200 oC. Unfortunately, the use of nitric acid or other oxidants restricts the use of the polyacetals to those powders which are not susceptible to undesirable oxidation. Other binder materials include polyoxalate and polymalonate polymers, which also are useful as rheological control agents in paste 15 formulations, as described in U.S. Patent No. 5,412,062 to Power et al. Polyalkylene carbonates, however, exhibit viscosity behavior that makes flow of the unformed metal/binder, ceramic/binder, or metal/ceramic/binder difficult. Many of the characteristics of materials and compositions useful 20 as binders are described in Shanefield, "Organic Additives and Ceramic Processing," (Kluwer Academic Publishers, Boston 1996). Desirable features include (1) easy burnout, (2) strong adhesion to the powder and good cohesive strength, (3) solubility in fluidizing liquid, and (4) low cost. The binder material must be suitable for a variety of process 25 conditions, since, for example, many powders must avoid exposure to air or water, or may require exposure to reducing gases or vacuum conditions, during processing. It is therefore an object of this invention to provide molding compositions having improved binder removal characteristics. 30 It is another object of this invention to provide molding compositions suitable for use in a wide range of processing conditions. 3 WO 99/05209 PCT/US98/15195 Summary Of The Invention Molding compositions including polyhydroxyalkanoates are provided. The use of polyhydroxyalkanoates as a binder in molding compositions provides improved binder removal in the finished molded 5 product, and offers a wide range of physical properties suitable for use in a variety of processing conditions. The composition preferably includes a powdered material, such as a metal powder, ceramic powder, or blend, admixed with a polyhydroxyalkanoate binder. The compositions are useful in powder processing techniques, such as injection molding, slip 10 casting, tape casting, or extrusion. Detailed Description Of The Invention Polyhydroxyalkanoate binders for use in molding compositions are provided, preferably for use in metal powder, ceramic powder, or metal/ceramic powder processing. 15 I. PHA Molding Compositions The molding compositions generally include one or more powdered materials and one or more polyhydroxyalkanoates or a solution thereof. The compositions may include additional (optional) components to enhance processing or properties of the end product. 20 1. Powdered Material The powdered material of the molding compositions disclosed herein can be selected from glasses, ceramics, metals, alloys, thermoplastic polymers, and combinations thereof. Metal powder, ceramic powder, and blends of metal and ceramic powder are preferred. 25 Powder materials useful in the molding compositions disclosed herein are described in German, "Powder Injection Molding," (Metal Powder Industries Federation, Princeton, New Jersey 1990) and German and Bose, "Injection Molding of Metals and Ceramics," (Metal Powder Industries Federation, Princeton, New Jersey 1997). 30 The term "powdered" as used throughout this disclosure refers to the form of the material prior to mixing it into the composition to be 4 WO 99/05209 PCT/US98/15195 molded, and is understood to include microparticles, microspheres, nanoparticles, flakes, and other particles of a size suitable for molding into larger products. The amount of powdered material present in the molding 5 composition preferably is between about 50% and 99.999%, and more preferably between about 70% and 99.999%, of the total dry weight of the composition. The particular material, form of the material, and fraction of material present in the composition can be readily selected by those of skill in the art based, for example, on the desired physical 10 properties of the end product and the particular molding process to be employed. 2. Polyhydroxyalkanoate Binder Several types of polyhydroxyalkanoates (PHAs) are known. It is useful to broadly divide the PHAs into two groups according to the length 15 of their side chains and according to their pathways for biosynthesis. Those with short side chains, such as polyhydroxybutyrate (PHB), a homopolymer of R-3-hydroxybutyric acid units, are crystalline thermoplastics; PHAs with long side chains are more elastomeric. The former polymers have been known for about seventy years (Lemoigne & 20 Roukhelman 1925), while the latter polymers are a relatively recent discovery (deSmet, et al., J. Bacteriol., 154:870-78 (1983)). Before this designation, however, PHAs of microbial origin containing both R-3 hydroxybutyric acid units and longer side chain units from C5 to C16 were identified (Wallen & Rowheder, Environ. Sci. Technol., 8:576-79 25 (1974)). A number of bacteria which produce copolymers of D-3 hydroxybutyric acid and one or more long side chain hydroxyacid units containing from five to sixteen carbon atoms have been identified more recently (Steinbuchel & Wiese, Appl. Microbiol. Biotechnol., 37:691-97 (1992); Valentin et al., Appl. Microbiol. Biotechnol., 36: 507-14 (1992); 30 Valentin et al., Appl. Microbiol. Biotechnol., 40:710-16 (1994); Abe et al., Int. J. Biol. Macromol., 16:115-19 (1994); Lee et al., Appl. Microbiol. Biotechnol., 42:901-09 (1995); Kato et al., Appl. Microbiol. 5 WO 99/05209 PCT/US98/15195 Biotechnol., 45:363-70 (1996); Valentin et al., Appl. Microbiol. Biotechnol., 46:261-67 (1996); U.S. Patent No. 4,876,331 to Doi). Useful examples of specific two-component copolymers include PHB-co 3-hydroxyhexanoate (Brandl et al., Int. J. Biol. Macromol., 11:49-55 5 (1989); Amos & McInerey, Arch. Microbiol., 155:103-06 (1991); U.S. Patent No. 5,292,860 to Shiotani et al.). Chemical synthetic methods have also been applied to prepare racemic PHB copolymers of this type for applications testing (WO 95/20614, WO 95/20615, and WO 96/20621). 10 As PHAs have become increasingly available, they have been examined for their suitability in applications where they serve as a processing aid. For example, the use of PHA latex film in the production of CRT tube components is described in WO 96/17369. A. Polymer Formulas 15 Suitable molecular weights of the polymers are between about 10,000 and 4 million Daltons. Preferable molecular weights are between about 50,000 and 1.5 million Daltons. The PHAs preferably contain one or more units of the following formula:
-OCRR
2
(CR
3
R
4 )nCO 20 wherein n is 0 or an integer; and wherein R 1 , R 2 , R 3 , and R 4 are independently selected from saturated and unsaturated hydrocarbon radicals, halo- and hydroxy substituted radicals, hydroxy radicals, halogen radicals, nitrogen substituted radicals, oxygen-substituted radicals, and hydrogen atoms. 25 Suitable monomeric units include hydroxybutyrate, hydroxyvalerate, hydroxyhexanoate, hydroxyheptanoate, hydroxyoctanoate, hydroxynonanoate, hydroxydecanoate, hydroxyundecanoate, and hydroxydodecanoate units. PHAs including monomers and polymers and derivatives of 3-hydroxyacids, 30 4-hydroxyacids and 5-hydroxyacids can be used. Representative PHAs are described in Steinbiichel & Valentin, FEMS Microbiol. Lett., 128:219 28 (1995). 6 WO 99/05209 PCT/US98/15195 B. Preparation of Polvhydroxvalkanoates The PHAs can be prepared from a biological source such as a microorganism which naturally produces the PHAs or which can be induced to produce the PHAs by manipulation of culture conditions and 5 feedstocks, or microorganisms or a higher organism such as a plant, which has been genetically engineered so that it produces PHAs. Methods which can be used for producing PHA polymers from microorganisms which naturally produce polyhydroxyalkanoates are described in U.S. Patent No. 4,910,145 to Holmes, et al.; Byrom, 10 "Miscellaneous Biomaterials" in Biomaterials (Byrom, ed.) pp. 333-59 (MacMillan Publishers, London 1991); Hocking and Marchessault, "Biopolyesters" in Chemistry and Technology of Biodegradable Polymers (Griffin, ed.) pp. 48-96 (Chapman & Hall, London 1994); Holmes, "Biologically Produced (R)-3-hydroxyalkanoate Polymers and 15 Copolymers" in Developments in Crystalline Polymers (Bassett, ed.) vol. 2, pp. 1-65 (Elsevier, London 1988); Lafferty et al., "Microbial Production of Poly-b-hydroxybutyric acid" in Biotechnology (Rehm & Reed, eds.) vol. 66, pp. 135-76 (Verlagsgesellschaft, Weinheim 1988); Miller & Seebach, Angew. Chem. Int. Ed. Engl. 32:477-502 (1993). 20 Methods for producing PHAs in natural or genetically engineered organisms are described by Steinbiichel, "Polyhydroxyalkanoic Acids" in Biomaterials (Byrom, ed.) pp. 123-213 (MacMillan Publishers, London 1991); Williams & Peoples, CHEMTECH, 26:38-44 (1996); Steinbichel & Wiese, Appl. Microbiol. Biotechnol., 37:691-97 (1992); U.S. Patent 25 Nos. 5,245,023; 5,250,430; 5,480,794; 5,512,669; 5,534,432 to Peoples and Sinskey; Agostini et al., Polym. Sci., Part A-1, 9:2775-87 (1971); Gross et al., Macromolecules, 21:2657-68 (1988); Dubois, et al., Macromolecules, 26:4407-12 (1993); Le Borgne & Spassky, Polymer, 30:2312-19 (1989); Tanahashi & Doi, Macromolecules, 24:5732-33 30 (1991); Hori et al., Macromolecules, 26:4388-90 (1993); Kemnitzer et al., Macromolecules, 26:1221-29 (1993); Hori et al., Macromolecules, 26:5533-34 (1993); Hocking & Marchessault, Polym. Bull., 30:163-70 7 WO 99/05209 PCTIUS98/15195 (1993); Xie et al., Macromolecules, 30:6997-98 (1997); and U.S. Patent No. 5,563,239 to Hubbs et al. Other polymer synthesis approaches including direct condensation and ring-opening polymerization of the corresponding lactones are described in Jesudason & Marchessault, 5 Macromolecules 27:2595-602 (1994); U.S. Patent No. 5,286,842 to Kimura; U.S. Patent No. 5,563,239 to Hubbs et al.; U.S. Patent No. 5,516,883 to Hori et al.; U.S. Patent No. 5,461,139 to Gonda et al.; and Canadian Patent Application No. 2,006,508. WO 95/15260 describes the manufacture of PHBV films, and U.S. Patent Nos. 4,826,493 and 10 4,880,592 to Martini et al. describe the manufacture of PHB and PHBV films. U.S. Patent No. 5,292,860 to Shiotani et al. describes the manufacture of the PHA copolymer poly(3-hydroxybutyrate-co-3 hydroxyhexanoate. C. Form and Selection of PHA Binder 15 A number of features of the polyhydroxyalkanoate polymers make them particularly attractive as binders for metal powder, ceramic powder or metal/ceramic powder processing. PHA binder formulations can be prepared using PHAs in their solid form, in a latex form, or in solution, for example, dissolved in a solvent such as acetone. PHAs can be 20 plasticized and blended with other polymers or agents. A variety of PHAs, having a wide range of polymer physical properties, can be produced, depending on the hydroxyacid monomer composition used (Steinbuchel & Valentin, FEMS Microbiol. Lett., 128:219-28 (1995)). The range of properties include, for example, 25 melting temperatures between about 40 "C and 180'C, glass transition temperatures between about -35 C to 5 'C, degrees of crystallinity between about 0% and 80%, and elongation to break between about 5 and 500%. The rate of crystallization can be controlled. Polyhydroxybutyrate, for example, has characteristics similar to those of 30 polypropylene, while polyhydroxyoctanoates (a copolymer of D-3 hydroxyoctanoate and D-3-hydroxyhexanoate) behave more as elastomers, and PHAs with longer side chains have characteristics similar to waxes. 8 WO 99/05209 PCTIUS98/15195 The range of PHA polymers available with melting temperatures ranging from 40 tol80*C provides additional flexibility in shape formation. PHAs can exist in at least two distinct physical forms, as amorphous granules or as crystalline solids. The tendency of the PHAs to 5 crystallize in terms of both final degree of crystallinity and rates of crystallization also varies with composition. PHA polymers offering rapid crystallization can be used for high green strength. These would include, for example PHB and PHBV, with the latter copolymer exhibiting the unique feature of isodimorphism. Where higher malleability is desired, 10 PHOs and other longer pendant group types could be used. This polymer class has a lower glass transition temperature, around -35 * C as compared to 5 °C for the PHB homopolymer, allowing them to be formulated as self lubricating. This in turn reduces the need for other additives to obtain suitable flow characteristics for the mixture fed to the shaping 15 system. One particularly useful form is as a latex of PHA in water. Evaporation of the water as the shapes are molded results in film formation as the PHA granules coalesce providing excellent binding. The PHAs are readily removed by thermal decomposition during the 20 subsequent thermal processing of the shaped parts. The range of PHA polymers available with melting temperatures ranging from 40-180* C provides additional flexibility in shape formation. The monomer compositions also affect solubility in organic solvents, allowing the choice of a wide range of solvents. Copolymers 25 of D-3-hydroxybutyrate and other hydroxyacid co-monomers have significantly different solubility characteristics from those of the PHB homopolymer. For example, acetone is not a good solvent for PHB but is very useful for dissolving D-3-hydroxybutyrate copolymers with D-3 hydroxyacids containing from 6 to 12 carbon atoms (Abe et al., Int. J. 30 Biol. Macromol. 16:115-19 (1994); Kato et al., Appl. Microbiol. Biotechnol., 45:363-70 (1996)). Mitomo et al., Reports on Progress in Polymer Physics in Japan, 37:128-29 (1994), describes the solubility of 9 WO 99/05209 PCT/US98/15195 copolyesters poly(3-hydroxybutyrate-co-4-hydroxybutyrate, containing from 15 to 75 mol. % 4-hydroxybutyrate residues, in acetone. A number of other solvents suitable for a range of PHAs are described in U.S. Patent No. 5,213,976 to Blauhut et al.; U.S. Patent No. 4,968,611 to 5 Traussnig; Japan Kokai Tokkyo Koho JP 95,135,985; Japan Kokai Tokkyo Koho JP 95,79,788; WO 93/23554; DE 19533459; WO 97/08931; and Brazil Pedido PI BR 93 02,312. E. Other Binder Components PHAs can be plasticized and blended with other polymers or 10 agents. Other, non-microbial, polymers having structures and decomposition temperatures similar to polyhydroxyalkanoates include polylactide (PLA) and polyglycolide (PGA). These polymers can be used in combination with or in place of PHA binders. The production and use of PLA are described extensively by Kharas et al., "Polymers of Lactic 15 Acid" in Plast. Microbes (Mobley, ed.) pp. 93-137 (Hanser, Munich, Germany (1994)). The ester oxygens of these polymers, PHAs, PLA, PGA, are polar and provide good bonding between the binder and the powder materials. 3. Additives 20 Binders used in molding compositions frequently include a blend of other components, such as lubricants, plasticizers, and adhesion agents. The PHA molding compositions disclosed herein can also include such additives. It is also understood that certain PHAs may be used in place of such additives in other compositions. 25 II. Methods of Using PHA Molding Compositions The PHA molding compositions can be used in forming techniques known in the art. The de-binding step described below can be adapted for use with these techniques as needed for the particular process, material, and product. 10 WO 99/05209 PCT/US98/15195 1. Forming Processes The PHA molding compositions can be used in forming techniques known in the art. These techniques include slip casting, tape casting, extrusion, injection molding, dry pressing and screen printing. These and 5 other powder processing techniques are described in German, "Powder Injection Molding," (Metal Powder Industries Federation, Princeton, New Jersey 1990) and German and Bose, "Injection Molding of Metals and Ceramics," (Metal Powder Industries Federation, Princeton, New Jersey 1997). Extrusion and injection molding are preferred processes for use 10 with the compositions described herein. One of skill in the art should readily be able to adapt known forming techniques for use with the PHA molding compositions disclosed herein. 2. PHA Binder Removal The de-binding step preferably includes heating the shaped powder 15 compact to a temperature approaching the decomposition temperature of the polyesters, which is remarkably constant for the PHAs despite varying pendant groups, so that temperature control experience is widely applicable over a range of PHA formulations. The decomposition involves formation of crotonic acid and its homologues. Careful 20 application of heat leading to slightly higher temperatures on the outside of the shaped powder compact causes the PHA powder to decompose so that degassing channels can be formed and subsequent processing can take place without deformation or void formation of the shape due to gas trapping. 25 In the case of PHAs containing unsaturated monomers, the alkenoic acids can be destroyed by thermal catalytic systems, by combustion, or a combination thereof. The need for air inflow, oxygen, or other oxidants is eliminated or reduced through the use of PHA binders, thereby reducing waste gas emissions and heat loss. Avoidance 30 of oxidants also minimizes undesirable oxidation of components such as metal powders. Alkenoic acids are also compatible with a reducing or inert atmosphere, when exposure to such atmospheres is desired. For 11 WO 99/05209 PCT/US98/15195 example, the use of reducing atmospheres is advantageous when using metal oxides or mixtures comprising metal oxides. In general, avoidance of the need for protective atmospheres or other gases simplifies the process and protects the constituent materials. 5 The rate of decomposition of the PHA can be controlled more easily than the combustion of other binding materials. Combustion requires diffusion of combustion product from the burning binder and diffusion of oxygen to it entail process control and other complexities that are obviated by the use of the PHA system. In other words, the unpredictable results of 10 combustion are avoided since oxygen penetration into the powder containing shape is no longer required. The PHA system also avoids carbon residues found in other binder systems containing polyolefin or polystyrene materials, thereby leading to fewer faults and greater strength in the final products. 15 PHAs may also be removed using a solvent process. A variety of application and processing options are provided, since a range of solvents for PHAs are available. The solvency characteristic of PHAs also allows for their removal from malformed compacts, unused tape, and other process waste, thereby reducing wastage. In addition, the PHAs are 20 made from renewable resources and degradable by enzymatic action produced by microorganisms in, for example, composting systems, providing another means of disposal of waste material. III. Applications for Using PHA Molding Compositions Preferred applications include the manufacture of ceramics, 25 lacquers, superconductors, and automotive parts. In one embodiment, an "ink" or "lacquer" containing low melting temperature and conducting metals or metal oxides can be applied above the melting point of the polymer and the "ink" allowed to solidify if desired to permit additional production steps. The ink and substrate can 30 then be brought to the decomposition temperature of the PHA at which point the PHA decomposes leaving a dense conductive strip. 12 WO 99/05209 PCT/US98/15195 Alternatively, a metal powder/PHA mixture can be applied as a coating or lacquer above the melting temperature of the PHA, allowed to solidify and the PHA removed by thermal decomposition. The use of solvent based PHA binder formulations will give similar flexibility including the 5 use of aqueous latexes. In another embodiment, a PHA form suitable for extrusion molding can be used as a container for powdered materials, such as the 1-2-3 superconductor, wherein the PHA is removed by thermal decomposition after shaping the powdered material. A particularly useful example is in the manufacture of superconducting tapes 10 or wires using yttrium oxide, barium carbonate, and cupric oxide with subsequent enrichment with oxygen (YBCO). The thin film techniques currently used can only produce YBCO tapes of about one meter in length. The ability to extrude such materials should be useful in manufacturing superconducting films or wires that are hundreds of meters 15 long and commercially suitable. The compositions and methods of preparation and use thereof described herein are further described by the following non-limiting examples. Example 1: BaTiO 3 Disk Made Using PHA Latex Binder 20 A PHA latex (18% solids, particle size between 0.2 and 1.0 p/m), which was prepared from Pseudomonas putida cells cultivated on fatty acids, was mixed with BaTiO 3 powder (Aldrich, particle size less than 2 Am) at a dry weight ratio of 1:19. The resulting paste was then freeze dried and further desiccated in a vacuum oven at 120 * C. The dried 25 paste was reground and compressed at 40,000 psi in 13 mm die mold to form a round disk. The disk was bisque-fired in air using the following heating profile: (1) heat from ambient to 1125 C at 3 C/min.; (2) soak at 1125 C for one hour; and (3) cool to room temperature. The fired disc retained its shape, free of visible 30 cracks or other defects. The measured weight loss of 5% indicated quantitative removal of the polymeric binder. 13 WO 99/05209 PCT/US98/15195 Example 2: A1 2 0 3 Disk Made Using PHA Latex Binder A PHA latex (18% solids, particle size between 0.2 and 1.0 pm), which was prepared from Pseudomonas putida cells cultivated on fatty acids, was mixed with A1 2 0 3 powder (Aldrich, particle size less than 10 5 pm) at a dry weight ratio of 1:19. The resulting paste was then freeze dried and further desiccated in a vacuum oven at 120 C. The dried paste was reground and compressed at 40,000 psi in 13 mm die mold to form a round disk. The disk was bisque-fired in air using the following heating profile: (1) heat from ambient to 10 1125 °C at 3 *C/min.; (2) soak at 1125 "C for one hour; and (3) cool to room temperature. The fired disc retained its shape, free of visible cracks or other defects. The measured weight loss of 5% indicated quantitative removal of the polymeric binder. Example 3: A1 2 0 3 Disk Made Using PHA Binder Solution 15 PHA purified from Pseudomonas putida cells cultivated on fatty acids, was dissolved in acetone to form a 10% wt./vol. solution. The PHA solution was mixed with A1 2 0 3 powder (Aldrich, particle size less than 10 pm) at a dry weight ratio of 1:19. The resulting paste was then freeze-dried and further desiccated in a vacuum oven at 120 C. The 20 dried paste was reground and compressed at 40,000 psi in 13 mm die mold to form a round disk. The disk was bisque-fired in air using the following heating profile: (1) heat from ambient to 1125 *C at 3* C/min.; (2) soak at 1125 C for one hour; and (3) cool to room temperature. The fired disc retained its shape, free of visible cracks or other defects. The 25 measured weight loss of 4.4% indicated removal of the polymeric binder. In a control experiment, omission of the binder solution resulted in a compressed part that disintegrated upon removal from the die mold. Firing of the compressed powder did not affect the weight or appearance of the powder. 14 WO 99/05209 PCT/US98/15195 Example 4: BaTiO 3 Disk Made Using PHA Binder Solution PHA purified from Pseudomonas putida cells cultivated on fatty acids, was dissolved in acetone to form a 10% wt./vol. solution. The PHA solution was mixed with BaTiO 3 powder (Aldrich, particle size less 5 than 2 /m) at a dry weight ratio of 1:19. The paste was then freeze-dried and further desiccated in a vacuum oven at 120 *C. The dried paste was reground and compressed at 40,000 psi in 13 mm die mold to form a round disk. The disk was bisque-fired in air using the following heating profile: (1) heat from ambient to 1125 *C at 3' C/min.; (2) soak at 1125 10 C for one hour; and (3) cool to room temperature. The fired disc retained its shape, free of visible cracks or other defects. The measured weight loss of 5% indicated quantitative removal of the polymeric binder. In a control experiment, omission of the binder solution resulted in a compressed part that disintegrated upon removal from the die mold. 15 Firing of the compressed powder did not affect the weight or appearance of the powder. Example 5: A1 2 0 3 Disk Made Using PHB Binder PHB homopolymer was mixed with A1 2 0 3 powder (Aldrich, particle size less than 10 pm) at a weight ratio of 1:19. The paste was 20 ground and compressed at 40,000 psi in a 13 mm die mold to form a round disk. The disk was bisque-fired in air using the following heating profile: (1) heat from ambient to 1125 *C at 3* C/min.; (2) soak at 1125 'C for one hour; and (3) cool to room temperature. The fired disc retained its shape, free of visible cracks or defects. The measured weight 25 loss of 5% indicated quantitative removal of the polymeric binder. Example 6: BaTiO 3 Disk Made Using PHB Binder PHB was mixed with BaTiO 3 powder (Aldrich, particle size less than 2 )um) at a weight ratio of 1:19. The powder mixture was ground and compressed at 40,000 psi in a 13 mm mold to form a round disk. 30 The disk was bisque-fired in air using the following heating profile: (1) 15 WO 99/05209 PCT/US98/15195 heat from ambient to 1125 C at 3 C/min.; (2) soak at 1125 * C for one hour; and (3) cool to room temperature. The fired disc retained its shape, free of visible cracks or other defects. The measured weight loss of 5% indicated quantitative removal of the polymeric binder. 5 Example 7: BaTiO 3 Disk Made Using PHBV Binder in a 1:19 Weight Ratio PHBV (12% HV content, Aldrich) was mixed with BaTiO 3 powder (particle size less than 2 ptm, Aldrich) at a weight ratio of 1:19. The powder mixture was ground and compressed at 40,000 psi in a 13 mm die 10 mold to form a round disk. The disk was bisque-fired in air using the following heating profile: (1) heat from ambient to 1125 "C at 3* C/min.; (2) soak at 1125 C for one hour; and (3) cool to room temperature. The fired disk retained its shape, free of visible cracks or defects. The measured weight loss of 4% indicated removal of the polymeric binder. 15 Example 8: BaTiO 3 Bar Made Using PHBV Binder in a 1:4 Weight Ratio PHBV (12% HV content, Aldrich) was mixed with BaTiO 3 powder (particle size less than 2 gm, Aldrich) at a weight ratio of 1:4. The powder mixture was ground and compressed at 12,000 psi in a die mold 20 at 175 'C to form a rectangular bar. The bar was bisque-fired in air using the following heating profile: (1) heat from ambient to 1125 C at 3 C/min.; (2) soak at 1125 * C for one hour; and (3) cool to room temperature. The fired bar retained its shape with some visible pits. The measured weight loss of 18.6% indicated removal of the polymeric 25 binder. Example 9: Gold Film Made Using PHA Latex Binder 100 mg gold powder (Aldrich, 1.5 to 3.0 1m, spherical) and 0.16 mg sodium carboxymethylcellulose (Aldrich, 3,000-6,000 cP at 1% in water) were added to a PHA latex (0.028 mL, 18% solids, particle size 16 WO 99/05209 PCT/US98/15195 between 0.2 and 1.0 Am) prepared from Pseudomonas putida cells cultivated on fatty acids. The resulting mixture was painted in a stenciled pattern onto a slightly porous white ceramic tile (25 x 50 x 0.5 mm). The painted tile then was bisque-fired in air using the following heating 5 profile: (1) heat from ambient to 750 °C at 10 °C/min.; (2) soak at 750 *C for one hour; and (3) cool to room temperature. Following cooling, the gold particles were found to be sintered to form a coherent film attached to the ceramic support. The film was electrically conductive, as evidenced by a measured resistance of less than 0.5 ohm across a 1 cm 10 gap. Example 10: Gold Disk Made Using PHA Binder Solution Gold powder (4.75 g, 0.8 to 1.5 Am spherical, Alfa Aesar) was combined with a solution of PHA (0.0975 g, from Pseudomonas putida cells cultured on fatty acids) dissolved in acetone (0.9 mL). The slurry 15 was dried in a warm oven and then further dried in vacuo at 75 C. The dried mixture was compressed into a 1 cm disk using a die mold (40,000 psi, 1 min.). The green part was then bisque-fired using the following heating profile: (1) heat from ambient to 750 C at 3 C/min.; (2) soak for 2 hours at 750 "C; and (3) cool to room temperature. The final 20 product was an intact, lustrous gold disk. Weight loss indicated 99.7% complete removal of the polymer binder. 17
Claims (21)
1. A composition comprising at least one powdered material admixed with at least one thermally decomposable polyhydroxyalkanoate.
2. The composition of claim 1 wherein the polyhydroxyalkanoate is a polymer of one or more subunits having the chemical formula: -OCRR 2 (CR 3 R 4 )nCO wherein n is 0 or an integer, and wherein R', R 2 , R 3 , and R 4 are each selected from saturated and unsaturated hydrocarbon radicals; halo- and hydroxy-substituted radicals; hydroxy radicals; halogen radicals; nitrogen substituted radicals; oxygen-substituted radicals; and hydrogen atoms.
3. The composition of claim 1 wherein the polyhydroxyalkanoate is selected from the group consisting of poly(hydroxybutyrate), polyhydroxybutyrate-co-hydroxyvalerate, polyhydroxybutyrate-co-4-hydroxybutyrate, polyhydroxybutyrate-co-3 hydroxyhexanoate, polyhydroxybutyrate-co-3-hydroxyheptanoate, and polyhydroxybutyrate-co-3-hydroxyoctanoate.
4. The composition of claim 1 wherein the polyhydroxyalkanoate is produced by a microbial fermentation process.
5. The composition of claim 1 wherein the polyhydroxyalkanoate is produced by a genetically engineered plant crop system.
6. The composition of claim 1 wherein the polyhydroxyalkanoate is produced by a chemical polymerization reaction.
7. The composition of claim 6 wherein the chemical polymerization reaction is a ring opening polymerization reaction.
8. The composition of claim 1 wherein the polyhydroxyalkanoate comprises a polymer selected from the group consisting of poly(lactic acid)s, poly(glycolic acid)s, copolymers thereof, and blends thereof. 18 WO 99/05209 PCTIUS98/15195
9. The composition of claim 1 wherein the powdered material is selected from the group consisting of glass, ceramics, metals, alloys, and mixtures thereof.
10. The composition of claim 9 wherein the powdered material is present in an amount between about 50% and 99.999% by weight based on total dry weight of the composition.
11. The composition of claim 9 wherein the powdered material is a ceramic present in an amount between about 70% to 99.999% by weight based on total dry weight of the composition.
12. The composition of claim 1 wherein the polyhydroxyalkanoate comprises a mixture of thermally depolymerizable polyhydroxyalkanoates.
13. The composition of claim 1 further comprising at least one thermally depolymerizable polymer other than polyhydroxyalkanoate.
14. The composition of claim 12 wherein the thermally depolymerizable polymer is selected from the group consisting of polycarbonates, polyolefins, polystyrenes, polyacetals, and waxes.
15. The composition of claim 1 wherein the polyhydroxyalkanoate is dispersed in water.
16. The composition of claim 1 wherein the polyhydroxyalkanoate is dissolved in a solvent or a mixture of solvents.
17. A method of a forming shaped product, the method comprising molding a composition comprising a powdered material admixed with at least one thermally decomposable polyhydroxyalkanoate or a solution thereof to form the shaped product.
18. The method of claim 17 wherein the powdered material is selected from the group consisting of glass, ceramics, metals, alloys, and mixtures thereof.
19. The method of claim 17 wherein the method of forming shaped products is selected from the group consisting of slip casting, tape casting, extrusion, injection molding, dry pressing, and screen printing. 19 WO 99/05209 PCT/US98/15195
20. The method of claim 17 further comprising heating the shaped product to remove essentially all of the polyhydroxyalkanoate from the product.
21. A molded article formed by a method comprising molding a composition comprising a powdered material admixed with at least one thermally decomposable polyhydroxyalkanoate or a solution thereof. 20
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-
1998
- 1998-07-22 WO PCT/US1998/015195 patent/WO1999005209A1/en active IP Right Grant
- 1998-07-22 US US09/120,940 patent/US6071998A/en not_active Expired - Lifetime
- 1998-07-22 EP EP98937977A patent/EP0998526B1/en not_active Expired - Lifetime
- 1998-07-22 DE DE69840594T patent/DE69840594D1/en not_active Expired - Lifetime
- 1998-07-22 ES ES98937977T patent/ES2325821T3/en not_active Expired - Lifetime
- 1998-07-22 CA CA002297179A patent/CA2297179C/en not_active Expired - Lifetime
- 1998-07-22 AT AT98937977T patent/ATE423812T1/en not_active IP Right Cessation
- 1998-07-22 JP JP2000504195A patent/JP3373841B2/en not_active Expired - Fee Related
- 1998-07-22 AU AU86600/98A patent/AU740068B2/en not_active Ceased
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2000
- 2000-06-05 US US09/587,745 patent/US6214920B1/en not_active Expired - Lifetime
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2002
- 2002-08-12 JP JP2002235283A patent/JP4074156B2/en not_active Expired - Fee Related
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- 2007-12-18 JP JP2007326603A patent/JP2008106284A/en active Pending
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WO1999005209A1 (en) | 1999-02-04 |
ES2325821T3 (en) | 2009-09-18 |
JP3373841B2 (en) | 2003-02-04 |
JP2003105181A (en) | 2003-04-09 |
CA2297179C (en) | 2007-03-13 |
JP4074156B2 (en) | 2008-04-09 |
ATE423812T1 (en) | 2009-03-15 |
JP2008106284A (en) | 2008-05-08 |
JP2001510871A (en) | 2001-08-07 |
US6214920B1 (en) | 2001-04-10 |
EP0998526A1 (en) | 2000-05-10 |
EP0998526B1 (en) | 2009-02-25 |
CA2297179A1 (en) | 1999-02-04 |
AU740068B2 (en) | 2001-10-25 |
US6071998A (en) | 2000-06-06 |
DE69840594D1 (en) | 2009-04-09 |
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